CASE CX57C Mini Excavator Service Repair Manual Instant Download

1
CX57C Mini Excavator SERVICE MANUAL
Part number 51452096 English March 2018 2018
CNH Industrial Italia S.p.A. All Rights Reserved.
2
Contents INTRODUCTION Engine.....................
..................................................
................ 10 10.001 Engine and
crankcase . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 10.1 10.106
Valve drive and gears . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
10.2 10.101 Cylinder heads . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 10.3 10.105 Connecting rods
and pistons . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 10.4 10.103 Crankshaft
and flywheel. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 10.5 10.216
Fuel tanks . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . 10.6 10.206 Fuel filters . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 10.7 10.218
Fuel injection system. . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
10.8 10.202 Air cleaners and lines . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . 10.9 10.254 Intake and exhaust
manifolds and muffler . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
10.10 10.501 Exhaust Gas Recirculation (EGR)
exhaust treatment. . . . . . . . . . . . . . . .
. . . . . . . . . . . . 10.11 10.400 Engine
cooling system . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . 10.12 10.414
Fan and drive . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
10.13 10.304 Engine lubrication system . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . 10.14 Hydraulic systems.......................
................................................
35 35.000 Hydraulic systems. . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . 35.1 35.300 Reservoir, cooler, and
filters. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . 35.2 35.106 Variable
displacement pump . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 35.3 35.359 Main
control valve . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
35.4 35.357 Pilot system . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 35.5 35.355 Hydraulic
hand control . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 35.6 35.356
Hydraulic foot control. . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
35.7 35.352 Hydraulic swing system . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . 35.8 35.353 Hydraulic travel system . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . 35.9 35.354 Hydraulic central
joint . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 35.10
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35.736 Boom hydraulic system . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
35.11
35.737 Dipper hydraulic system. . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
35.12
35.738 Excavator and backhoe bucket hydraulic
system . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . .
35.13
35.734 Tool quick coupler hydraulic system . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . .
35.14
35.360 Hammer and rotating bucket hydraulic
system . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . .
35.15
35.739 Swing arm hydraulic system . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. 35.741 Dozer blade cylinders . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. .
35.16 35.17
Pneumatic system .................................
.....................................
36 36.100 Pneumatic system. . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . 36.1 Frames and ballasting
..................................................
............... 39 39.140 Ballasts and
supports . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . 39.1 Tracks and
track suspension..................................
...................... 48 48.100 Tracks . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
48.1 48.130 Track frame and driving wheels . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
48.2 48.134 Track tension units . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . 48.3 48.138 Track rollers . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 48.4 Cab
climate control ..................................
................................... 50 50.100
Heating . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . 50.1 50.200 Air conditioning. . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . 50.2 Electrical
systems...........................................
............................ 55 55.000
Electrical system . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. 55.1 55.100 Harnesses and connectors. . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . 55.2 55.525 Cab engine controls . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . 55.3 55.015 Engine control
system. . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . 55.4 55.201
Engine starting system . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
55.5 55.301 Alternator. . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . 55.6 55.302 Battery. .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. 55.7 55.011 Fuel tank system . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 55.8
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55.014 Engine intake and exhaust system. . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
55.9 55.012 Engine cooling system . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . 55.10 55.013 Engine oil system . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . 55.11 55.640 Electronic modules
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 55.12 55.512 Cab
controls. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
55.13 55.036 Hydraulic system control . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . 55.14 55.524 Cab controls (Lift arm, Boom,
Dipper, Bucket) . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . .
55.15 55.518 Wiper and washer system. . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
55.16 55.404 External lighting . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . 55.17 55.514 Cab lighting . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . 55.18 55.408
Warning indicators, alarms, and instruments . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . 55.19 55.DTC FAULT CODES . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 55.20 Booms, dippers,
and buckets ......................................
................. 84 84.910 Boom . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
84.1 84.912 Dipper arm . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 84.2 84.100 Bucket . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
84.3 Dozer blade and arm..........................
.........................................
86 86.110 Dozer blade . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 86.1 Platform, cab, bodywork,
and decals .......................................
...... 90 90.150 Cab . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 90.1 90.120
Mechanically-adjusted operator seat. . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . 90.2 90.105
Machine shields and guards . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 90.3
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INTRODUCTION
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INTRODUCTION Foreword - Important notice
regarding equipment servicing All repair and
maintenance work listed in this manual must be
carried out only by qualified dealership
personnel, strictly complying with the
instructions given, and using, whenever possible,
the special tools. Anyone who performs repair and
maintenance operations without complying with the
procedures provided herein shall be responsible
for any subsequent damages. The manufacturer and
all the organizations of its distribution chain,
including - without limitation - national,
regional, or local dealers, reject any
responsibility for damages caused by parts and/or
components not approved by the manu- facturer,
including those used for the servicing or repair
of the product manufactured or marketed by the
manufacturer. In any case, no warranty is given
or attributed on the product manufactured or
marketed by the manufacturer in case of damages
caused by parts and/or components not approved by
the manufacturer. The manufacturer reserves the
right to make improvements in design and changes
in specifications at any time without notice and
without incurring any obligation to install them
on units previously sold. Specifications,
descriptions, and illustrative material herein
are as accurate as known at time of publication
but are subject to change without notice. In case
of questions, refer to your CASE CONSTRUCTION
Sales and Service Networks.
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8
INTRODUCTION
Safety rules
Personal safety This is the safety alert
symbol. It is used to alert you to potential
personal injury hazards. Obey all safety
messages that follow this symbol to avoid
possible death or injury.
Throughout this manual you will find the signal
words DANGER, WARNING, and CAUTION followed by
special in- structions. These precautions are
intended for the personal safety of you and those
working with you. Read and understand all the
safety messages in this manual before you operate
or service the machine.
DANGER indicates a hazardous situation that, if
not avoided, will result in death or serious
injury. WARNING indicates a hazardous situation
that, if not avoided, could result in death or
serious injury. CAUTION indicates a hazardous
situation that, if not avoided, could result in
minor or moderate injury.
FAILURE TO FOLLOW DANGER, WARNING, AND CAUTION
MESSAGES COULD RESULT IN DEATH OR SERIOUS
INJURY. Machine safety NOTICE Notice indicates
a situation that, if not avoided, could result in
machine or property damage. Throughout this
manual you will find the signal word Notice
followed by special instructions to prevent
machine or property damage. The word Notice is
used to address practices not related to personal
safety. Information NOTE Note indicates
additional information that clarifies steps,
procedures, or other information in this
manual. Throughout this manual you will find the
word Note followed by additional information
about a step, procedure, or other information in
the manual. The word Note is not intended to
address personal safety or property damage.
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INTRODUCTION Safety rules - General
information Cleaning Clean the metal parts with
cleaning solution that meets the standard and
steam cleaning. (except for bearings) After
cleaning, dry well, and inject oil in all
parts. Also inject oil into the bearings after
drying. Inspection When disassembling parts,
check all the parts. If there are any worn or
damaged parts, replace them. Inspect carefully
to prevent initial breakdowns. Bearing Replace
any loose bearings. Air dry bearings before
installing them. Needle bearing When inserting
needle bearings, be very careful not to damage
them. Apply grease to the section where the
needle bearing will be inserted. Gear Check that
there is no wear and no damage. Oil seal,
O-ring, gasket Always install new oil seals,
O-rings, and gaskets. Apply grease to sections
where oil seals and O-rings will be
inserted. Shaft Check that there is no wear and
no damage. Check the bearings and check for
damaged oil seals on the shaft. Service
parts Install CASE CONSTRUCTION genuine service
parts. When placing an order, check the parts
catalog. It contains the CASE CONSTRUCTION
genuine part numbers. Any breakdowns arising
from the installation of non-genuine parts are
not covered by the warranty. Lubricants (fuel,
hydraulic oil) Use the oil from the specified
company or specified in the operator's manual or
service Manual. Any breakdowns arising from any
fuel or hydraulic oil other than those specified
are not covered by the warranty.
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10
INTRODUCTION Safety rules - Personal
safety Preliminary warnings to maintenance
operation
WARNING Avoid injury! Shut off the engine, remove
the key, and make sure all machine motion stops
before you service the machine. Failure to
comply could result in death or serious
injury. W1128B
WARNING Improper operation or service of this
machine can result in an accident. Assign a
supervisor to direct worksite operations. Agree
on all safety measures, procedures, and suitable
hand signals. Failure to comply could result in
death or serious injury. W0287A
CAUTION Pinch hazard! Always use suitable tools
to align mating parts. DO NOT use your hand or
fingers. Failure to comply could result in minor
or moderate injury. C0044A
Personal Protective Equipment (PPE)
WARNING Avoid injury! Use Personal Protective
Equipment (PPE), including protective goggles,
gloves, and safety footwear. Failure to comply
could result in death or serious injury. W1036A
Lifting operation
WARNING Crushing hazard! The lifting systems must
be operated by qualified personnel who are aware
of the correct procedures to follow. Make sure
all lifting equipment is in good condition, and
all hooks are equipped with safety
latches. Failure to comply could result in death
or serious injury. W0256A
WARNING Heavy objects! Lift and handle all heavy
components using lifting equipment with adequate
capacity. Always support units or parts with
suitable slings or hooks. Make sure the work area
is clear of all bystanders. Failure to comply
could result in death or serious injury. W0398A
WARNING Improper operation or service of this
machine can result in an accident. Raised
equipment or machine movement without an operator
can cause serious injury. Always do the
following before performing any maintenance Park
the machine on flat, level ground. Lower the
attachment to the ground. Shut down the engine
and remove the ignition key. Lock the
tracks. Failure to comply could result in death
or serious injury. W0944D
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INTRODUCTION
WARNING Tip-over hazard! Only raise the track as
little as necessary. Failure to comply could
result in death or serious injury. W0276A
Hydraulic system
WARNING Burn hazard! Before performing any
service on the hydraulic system, you must allow
it to cool. Hydraulic fluid temperature should
not exceed 40 C (104 F). Failure to comply
could result in death or serious injury. W0241A
WARNING Pressurized fluid can penetrate the skin
and cause severe injuries. The grease in the
cylinder is under high pressure. Never loosen the
grease fitting adaptor completely in order to
speed up the flow of grease. Failure to comply
could result in death or serious injury. W0261A
WARNING Pressurized system! Before attempting any
service procedure, it is your responsibility to
know the number of accumulators on the machine,
and the correct procedure for releasing the
pressure of each accumulator. Failure to comply
could result in death or serious injury. W0136A
Battery
WARNING Battery acid causes burns. Batteries
contain sulfuric acid. Avoid contact with skin,
eyes or clothing. Antidote (external) Flush with
water. Antidote (eyes) flush with water for 15
minutes and seek medical attention immediately.
Antidote (internal) Drink large quantities of
water or milk. Do not induce vomiting. Seek
medical attention immediately. Failure to comply
could result in death or serious injury. W0111A
WARNING Battery gas can explode! To prevent an
explosion 1. Always disconnect the negative (-)
battery cable first. 2. Always connect the
negative (-) battery cable last. 3. Do not short
circuit the battery posts with metal objects. 4.
Do not weld, grind, or smoke near a
battery. Failure to comply could result in death
or serious injury. W0011A
Fluids
WARNING Hazardous chemicals! Coolant can be
toxic. Avoid contact with skin, eyes, and
clothing. Antidotes EXTERNAL - Rinse thoroughly
with water. Remove soiled clothing. INTERNAL -
Rinse the mouth with water. DO NOT induce
vomiting. Seek immediate medical attention. EYES
- Flush with water. Seek immediate medical
attention. Failure to comply could result in
death or serious injury. W0282A
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INTRODUCTION
WARNING Burn hazard! Hot coolant can spray and
scald if you remove the radiator or deaeration
tank cap while the system is hot. To remove the
cap allow the system to cool, turn the cap to
the first notch, and wait for all pressure to
release. Remove the cap only after all pressure
has released. Failure to comply could result in
death or serious injury. W0367A
WARNING Escaping fluid! Hydraulic fluid or diesel
fuel leaking under pressure can penetrate the
skin and cause infection or other injury. To
prevent personal injury Relieve all pressure
before disconnecting fluid lines or per- forming
work on the hydraulic system. Before applying
pressure, make sure all connections are tight
and all components are in good condition. Never
use your hand to check for suspected leaks under
pressure. Use a piece of cardboard or wood for
this purpose. If injured by leaking fluid, see
your doctor immediately. Failure to comply could
result in death or serious injury. W0178A
WARNING Chemical hazard! When handling fuel,
lubricants, and other service chemicals, follow
the manufacturer's instructions. Wear Personal
Protective Equipment (PPE) as instructed. Do not
smoke or use open flame. Collect fluids in
proper containers. Obey all local and
environmental regulations when disposing of
chemi- cals. Failure to comply could result in
death or serious injury. W0371A
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SERVICE MANUAL Engine CX57C Cab - Tier IV final
engine
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14
Engine - Engine and crankcase
Engine sensors
SMIL17MEX3017HB 2
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15
Engine - Engine and crankcase
Component Reference
1. EGR temperature sensor
Electrical system - Component identification -
EGR and intake temperature sensor (55.000)
2. Intake throttle valve
Electrical system - Component identification -
Intake throttle valve (55.000)
3. Intake temperature sensor
Electrical system - Component identification -
EGR and intake temperature sensor (55.000)
Electrical system - Component identification -
Crankshaft speed sensor (55.000)
4. Crankshaft speed sensor
5. EGR valve connector
Electrical system - Component identification -
EGR valve (55.000)
6. Engine oil pressure switch
Electrical system - Component identification -
Engine oil pressure switch (55.000)
7. Fuel temperature sensor
Electrical system - Component identification -
Fuel temperature sensor (55.000)
-
8. Pump discharge control valve
9. Camshaft speed sensor
Electrical system - Component identification -
Camshaft speed sensor (55.000)
10. Rail pressure sensor
Electrical system - Component identification -
Rail pressure sensor (55.000)
11. Coolant temperature sensor
Electrical system - Component identification -
Coolant temperature sensor (55.000) Engine
coolant temperature sensor and switch - Remove
(55.012)
12. New air temperature sensor
Electrical system - Component identification -
New air temperature sensor (55.000)
13. EGR pressure sensor
Electrical system - Component identification -
EGR pressure sensor (55.000)
14. Exhaust temperature sensor
Electrical system - Component identification -
Exhaust temperature sensor (55.000)
15. DPF inlet temperature sensor
Electrical system - Component identification -
DPF inlet temperature sensor (55.000)
16. DPF middle temperature sensor
Electrical system - Component identification -
DPF middle temperature sensor (55.000)
17. DPF differential pressure sensor
Electrical system - Component identification -
DPF differential pressure sensor (55.000)
18. Fuel injectors
Electrical system - Component identification -
Fuel injection system (55.000)
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Engine - Engine and crankcase
Engine - Exploded view
SMIL16MEX3410H 1
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17
Engine - Engine and crankcase

1. Cylinder block
2. Camshaft bushing
3. Gear case
4. Gear case cover
5. Front crankshaft seal
6. Tappets
7. Camshaft
8. Camshaft gear key
9. Camshaft end plate
10. Camshaft gear
11. Idler gear shaft (A)
12. Idler gear (A)
13. Idler gear bushing (A)
14. Idler gear plate (B)
15. Idler gear shaft (B)
16. Idler gear (B)
17. Idler gear bushing (B)
18. Oil pickup gasket
19. Oil pickup

1. Crankshaft gear key
2. Crankshaft gear
3. Crankshaft pulley
4. Main bearing inserts
5. Main bearing cap
6. Oil pan spacer
7. Oil pan
8. Thrust bearings
9. Flywheel
10. Connecting rod cap
11. Connecting rod bearing inserts
12. Connecting rod
13. Wrist pin bushing
14. Circlip
15. Wrist pin
16. Piston
17. Oil ring
18. Second compression ring
19. Top compression ring

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18
Engine - Engine and crankcase
Engine - Remove
WARNING Avoid injury! Shut off the engine, remove
the key, and make sure all machine motion stops
before you service the machine. Failure to
comply could result in death or serious
injury. W1128B
WARNING Chemical hazard! Use caution when opening
the quick coupler cap from the load port. There
may be product left in the port. Failure to
comply could result in death or serious
injury. W1039A
WARNING Crushing hazard! The lifting systems must
be operated by qualified personnel who are aware
of the correct procedures to follow. Make sure
all lifting equipment is in good condition, and
all hooks are equipped with safety
latches. Failure to comply could result in death
or serious injury. W0256A
WARNING Heavy objects! Lift and handle all heavy
components using lifting equipment with adequate
capacity. Always support units or parts with
suitable slings or hooks. Make sure the work area
is clear of all bystanders. Failure to comply
could result in death or serious injury. W0398A
WARNING Burn hazard! Before performing any
service on the hydraulic system, you must allow
it to cool. Hydraulic fluid temperature should
not exceed 40 C (104 F). Failure to comply
could result in death or serious injury. W0241A
WARNING Escaping fluid! Hydraulic fluid or diesel
fuel leaking under pressure can penetrate the
skin and cause infection or other injury. To
prevent personal injury Relieve all pressure
before disconnecting fluid lines or per- forming
work on the hydraulic system. Before applying
pressure, make sure all connections are tight
and all components are in good condition. Never
use your hand to check for suspected leaks under
pressure. Use a piece of cardboard or wood for
this purpose. If injured by leaking fluid, see
your doctor immediately. Failure to comply could
result in death or serious injury. W0178A
WARNING Chemical hazard! When handling fuel,
lubricants, and other service chemicals, follow
the manufacturer's instructions. Wear Personal
Protective Equipment (PPE) as instructed. Do not
smoke or use open flame. Collect fluids in
proper containers. Obey all local and
environmental regulations when disposing of
chemi- cals. Failure to comply could result in
death or serious injury. W0371A
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19
Engine - Engine and crankcase

• Set the battery disconnect switch to O position
  (OFF position) to cut off any power supply in
  the electrical system of the machine. (For
  details, see Mechanical battery isolator -
  Dynamic description (55.302))
• Discharge the air conditioning system (refer to
  Air con- ditioning - Discharging (50.200)).
• Remove the Radiator. For details, see Radiator -
  Re- move (10.400).
• Loosen the clamps and remove the cab heating
  hoses
• (2).
• Loosen the clamp and remove the fuel hose (3)
  from the fuel filter (1).

SMIL16MEX3552BB 1

• Close the fuel pre-filter cock (1).
• Loosen the clamp and remove the fuel pre-filter
  hose
• (2) from the fuel pre-filter (3).
• Use a wrench 13 mm to loosen the bolts (4),
  and then remove the fuel pre-filter (3).

SMIL16MEX3553AB 2
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20
Engine - Engine and crankcase

• Use a wrench 17 mm to disconnect the two hoses
  (3)
• from the air conditioning compressor (1).
• Disconnect the electrical connector CN-28 (2)
  from the air conditioning compressor (1).
• Remove the screw (5) then remove the electrical
  con- nector (4) from the air conditioning
  compressor.

SMIL16MEX3554BB 3

1. Use a wrench 17 mm to remove the bolt and then
   disconnect the earth strap (2) from the engine.
2. Disconnect the electrical connector CN-145 (1) of
   the electrical fuel feed pump.

SMIL16MEX3555AB 4

1. Disconnect the electrical connector CN-302 (1).
2. Disconnect the electrical connector CN-304 (1).
3. Disconnect the electrical connector CN-301 (3).
4. Disconnect the electrical connector CN-303 (4).

SMIL16MEX3556AB 5
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21
Engine - Engine and crankcase
18. Disconnect the electrical connector CD-18 (1)
of the engine oil pressure switch.
SMIL16MEX3557AB 6
19. Disconnect the electrical connector CN-80 (1)
of the pre-heater glow plugs.
SMIL16MEX3558AB 7
20. Disconnect the electrical connector CD-10 (1)
from the air cleaner.
SMIL16MEX3559AB 8

• Disconnect the two electrical connectors CN_300B
  (1)
• and CN-300C (4) from the air exhaust muffler (3).
• Disconnect the electrical connector CN-300A (2)
  from the air exhaust muffler (3).

SMIL18MEX0273AB 9
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22

• Engine - Engine and crankcase
• Move the cap.
• Use a wrench 13 mm to remove the nut and
  discon- nect the wire (1).
• Disconnect the electrical connector (2) from the
  alter- nator.

SMIL16MEX3562AB 10

1. Remove the nut to disconnect the wire (1).
2. Move the cap and then remove the nut to
   disconnect the wires (2) and (3).

SMIL16MEX3538AB 11
28. Loosen the clamp (1) and remove the air hose
(2) from the air cleaner.
SMIL16MEX3561AB 12

1. Drain the hydraulic oil.
2. Use a wrench 19 mm to disconnect the hose (1).
3. Use a wrench 22 mm to disconnect the hose (3).
4. Use a wrench 24 mm to disconnect the hoses
   (2).
5. Use a wrench 24 mm to disconnect the hose (5).
6. Use a wrench 24 mm to disconnect the hoses (4).

SMIL16MEX3491AB 13
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Engine - Engine and crankcase

• Mark the pump and hoses so that the connectors
  match at the time of assembly.
• Use caps and plugs to cover the pump and hoses to
  prevent any entry of water, dust or dirt.
• Clean the pump and hoses by spraying them with a
  parts cleaner to prevent scratches and prevent
  dirt from accumulating on the connectors.
• Loosen the clamp (1) to disconnect the suction
  hose
• (2).

SMIL16MEX3490AB 14

1. Install the two hooks (1) into the engine lift
   bracket, and then use the wire rope or chain and
   lift-crane to secure the engine.
2. Install the lift strap (2) around the pump (3)
   and insert it into the hook.

SMIL16MEX3563BB 15
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Engine - Engine and crankcase

• Use a box wrench 24 mm to remove the four
  bolts
• (1).
• Remove the engine (2).

SMIL16MEX3564BB 16
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25

• Engine - Engine and crankcase
• Engine - Disassemble
• Prepare a clean, flat working surface on a
  workbench large enough to accommodate the engine
  components. Discard all used gaskets, O-rings
  and seals. Use new gaskets, O-rings and seals on
  reassembly of engine.
• NOTICE identify all parts and their location
  using an ap- propriate method. It is important
  that all parts are returned to the same position
  during the reassembly process.
• If the engine will be completely disassembled,
  the fol- lowing preliminary steps should be
  performed.
• Disconnect the battery cables at the battery.
  Always disconnect the negative (-) cable first.
• Remove the throttle cable, electrical
  connections, in- take and exhaust system
  connections, and fuel supply lines from the
  engine.
• Remove the alternator. (Refer to Alternator -
  Remove (55.301))
• Drain the engine coolant from the radiator and
  cylinder block. Remove the cooling system
  components from the engine.
• Remove the engine from the machine. Mount the en-
  gine to a suitable engine repair stand having
  adequate weight capacity.
• NOTICE be sure to secure the engine solidly to
  prevent injury or damage to parts due to the
  engine falling during work on the engine.
• Clean the engine by washing with solvent, air or
  steam cleaning. Carefully operate so as to
  prevent any for- eign matter or fluids from
  entering the engine or any fuel system or
  electrical components remaining on the engine.
• Drain the engine oil into a suitable container.
  Remove the oil filter.
• Remove the cylinder head. (Refer to Cylinder
  heads
• - Disassemble (10.101))
• Remove fuel supply pump if necessary. (Refer to
  High pressure pump - Remove (10.218))
• Remove the starter motor. (Refer to Engine
  starter - Remove (55.201))

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26

• Engine - Engine and crankcase
• Removal of timing gear case cover
• Remove the bolt and washer retaining the
  crankshaft pulley.
• NOTICE use care not to damage the threads in the
  end of the crankshaft when removing the
  crankshaft pulley.
• Remove the crankshaft pulley using a gear puller.
• Remove the bolts that retain the gear case cover
  (1) to the cylinder block and oil pan.
• Remove the gear case cover (1).

SMIL16MEX3411AB 1

• Removal of timing gears
• Remove the bolts from the idler gear shaft (1).
  Remove the plate (5), the idler gear shaft (1),
  the idler gears (2) (4), and bushings (3).
• Do not remove the crankshaft gear unless it is
  dam- aged and requires replacement. If the gear
  must be removed, remove it using a gear puller.
• Removal of the camshaft gear requires the
  camshaft be removed and placed in a press. Do
  not remove the camshaft gear unless it or the
  camshaft is damaged and requires replacement.
  Refer to the removal of the camshaft.

SMIL16MEX3414BB 2
4. Remove the supply pump drive gear using a gear
puller.
SMIL16MEX3415AA 3
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Engine - Engine and crankcase

• Removal of oil pan
• Invert the engine (oil pan up) on the engine
  stand.
• Remove the oil pan (1).

SMIL16MEX3416BB 4
3. Remove the oil pickup tube (1) and O-ring (2).
SMIL16MEX3417BB 5
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Engine - Engine and crankcase

• Removal of camshaft
• Before removing the camshaft, check the camshaft
  end play.
• Method A Install a dial indicator (1) on the
  cylinder block. Move the camshaft (2) back and
  forth to mea- sure the end play. Record the
  measurement. Refer to Valve drive and gears -
  Service limits (10.106) for the service limit.

SMIL16MEX3418AB 6
Method B Use a feeler gauge to measure the
clear- ance between the thrust plate (1) and
front camshaft bearing (2). Refer to Valve drive
and gears - Ser- vice limits (10.106) for the
service limit.

SMIL16MEX3419AB 7

1. Remove the two bolts (3) retaining the camshaft
   thrust plate (1).
2. Rotate the engine in the engine stand so that
   gravity causes the tappets (5) to drop away from
   the camshaft lobes.

NOTE rotate the camshaft at least two turns to
bump any sticking tappets away from the
camshaft. 4. Slowly pull the camshaft (2)
assembly out of the engine being careful not to
damage the front camshaft bush- ing. NOTE if
the engine is not installed on an engine repair
fix- ture, stand the engine upright on the
flywheel end mounting flange. Rotate the
camshaft at least two turns to bump the tappets
out of the way to prevent the tappets from
interfer- ing with the removal of the
camshaft. The tappets are mushroom shaped and
must be removed from inside the engine crankcase.
SMIL16MEX3420AB 8

1. Remove the tappets. Mark the tappets so they can
   be reinstalled in the same location.
2. Remove the camshaft drive gear (4) only if the
   gear or camshaft require replacement. Use a
   knife-edge puller and a press to remove the
   gear. The gear is a shrink-fit and will need to
   be heated to 180 200 C (356 392 F) to
   remove.

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29

• Engine - Engine and crankcase
• Removal of gear case or front plate
• NOTE the camshaft must be removed before
  removing the gear case. See Removal of camshaft.
• Remove the oil pump.
• NOTE it is not necessary to remove the fuel
  supply pump from the gear case to remove the
  gear case. If the fuel sup- ply pump does not
  need to be repaired, leaving it mounted to the
  timing gear case will eliminate the need to
  re-time it during assembly. Refer to High
  pressure pump - Re- move (10.218).
• Remove the bolt (4).
• Remove the gear case (1) from the cylinder block.
  Thoroughly clean all old sealant from the mating
  sur- faces.
• Inspect and measure the camshaft bushing. Refer
  to Valve drive and gears - Service limits
  (10.106) for the service limit. If damaged or
  worn beyond service limits, remove the camshaft
  bushing (3).
• Remove two O-rings (2).

SMIL16MEX3421BB 9
DISASSEMBLY OF CRANKSHAFT AND PISTON
COMPONENTS Removal of pistons NOTICE keep the
piston pin parts, piston assemblies, and
connecting rod assemblies together to be returned
to the same position during the reassembly
process. Label the parts using an appropriate
method. NOTICE engines with high operating hours
may have a ridge near the top of the cylinders
that will catch the piston rings and make it
impossible to remove the pistons. Use a suitable
ridge reamer to remove ridges and carbon prior to
removing the pistons. NOTE pistons can fall
from cylinder block if the engine is inverted.
Rotate the engine so the connecting rods are
horizontal before removing the connecting rod
caps.
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Engine - Engine and crankcase

• Using a feeler gauge, measure the connecting rod
  side clearance as shown. Refer to Connecting rod
  and piston - Service limits (10.105) for the
  standard limit. If the measurement is out of
  specification, replace the crankshaft,
  connecting rod, or both.
• Measure bearing oil clearance prior to removing
  the pistons and connecting rods to determine
  extent of wear. Record the measurements.
• NOTICE mark the connecting rod caps and
  connecting rods so the caps and connecting rods
  stay together.

SMIL16MEX3423AA 10

• Remove the bearing cap. Do not remove the bear-
  ing inserts at this time.
• Wipe oil from the bearing insert and crankshaft
  journal surfaces.
• Place a piece of PLASTIGAGE (1) along the full
  width of the bearing insert.
• NOTICE do not rotate the crankshaft when using
  PLASTI- GAGE. A false reading may result.

SMIL16MEX3424AB 11

• Reinstall bearing cap and tighten to
  specification. Refer to Engine - Torque for
  special use (10.001).
• Remove bearing cap.
• Compare the width of the flattened PLASTIGAGE
  to the graduation marks on the package (1). The
  mark that most closely matches the width of the
  flat- tened PLASTIGAGE will indicate the
  bearing oil clearance.
• Repeat with remaining connecting rods.
• NOTICE do not allow the connecting rod to
  contact the crankshaft journal during piston
  removal. Damage to the bearing journal may
  result.

SMIL16MEX3425AB 12
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Engine - Engine and crankcase

1. Use a wooden dowel against the connecting rod and
   tap the piston/connecting rod assembly out of
   the cylin- der.
2. Mark the cylinder number on the piston and
   connecting rod.
3. Remove the bearing inserts (2).
4. Remove the compression rings (3) from the piston
   us- ing a piston ring expander.
5. Remove the oil ring (4) from the piston using a
   piston ring expander.
6. Remove the circlips (5) from the wrist pin.
7. Remove the wrist pin (6) and connecting rod (8)
   from the piston (9).
8. Repeat the steps until all pistons are removed
   and dissembled.

SMIL16MEX3426BB 13

• Removal of crankshaft
• Remove the flywheel (1) from the crankshaft.
• Remove the bolts from the rear oil seal assembly
  (2) (3). Remove the assembly from the engine.

SMIL16MEX3427AB 14

• Before removing the main bearing caps, measure
  the crankshaft end play. Use either of the
  following two methods.
• Method A Install a dial gauge (1) on the
  cylinder block. Move the crankshaft (2) in and
  out to measure the end play. Record the
  measurement.

SMIL16MEX3428AB 15
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